Reaction-Injection-Molded Cart and Method of Manufacture

ABSTRACT

One advantageous embodiment of the present invention is a reaction-injection-molded galley cart ( 10 ) for an aircraft. This cart ( 10 ) includes a body, which is configured to move along a passenger aisle of the aircraft. The body is comprised of a one-piece plastic shell ( 12 ) having a first side portion ( 28 ), a second side portion ( 30 ) spaced apart from the first side portion ( 28 ), a top side portion ( 24 ) extending between the first side portion ( 28 ) and the second side portion ( 30 ), and a bottom side portion ( 32 ) extending between the first side portion ( 28 ) and the second side portion ( 30 ). This one-piece plastic shell ( 12 ) includes at least one layer ( 36 ) of a reaction-injection-molded material.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is related to U.S. application Ser. No.10/813,765 (Applicant Disclosure No. 03-0074) entitled “AIRCRAFT GALLEYCARTS AND ASSOCIATED METHODS OF MANUFACTURE,” U.S. application Ser. No.10/651,278 (Applicant Disclosure No. 02-1417) entitled “SIDEWALL PANELINTEGRATED WITH INSULATION AND AIR DUCTS,” and U.S. application Ser. No.10/666,109 (Applicant Disclosure No. 02-1033), entitled “REACTIONINJECTION MOLDED MEMBERS AND METHOD OF FORMING” the disclosures of whichare incorporated by reference herein.

TECHNICAL FIELD

The present invention relates generally to galley carts for storing andserving food on aircrafts, and more particularly to areaction-injection-molded cart having substantial thermal insulation andlightweight characteristics.

BACKGROUND OF THE INVENTION

Commercial airlines are well known for utilizing galley carts fortransporting meals, maintaining those meals within a predeterminedtemperature range, and dispensing those meals to the passengers.Existing galley carts typically are manufactured by hand. The typicalwall construction of a galley cart comprises a PVC or honeycomb core andan aluminum skin covering that core.

It would be desirable to provide a reaction-injection molded cart havingimproved thermal insulation characteristics and a substantially lowmanufacturing cycle time, as well as minimized costs associatedtherewith.

SUMMARY OF THE INVENTION

One embodiment of the present invention is a reaction-injection-moldedgalley cart (“RIM cart”) for an aircraft. The RIM cart includes a body,which is configured to move along a passenger aisle of the aircraft. Thebody is comprised of a one-piece plastic shell having a first sideportion, a second side portion spaced apart from the first side portion,a top side portion extending between the first side portion and thesecond side portion, and a bottom side portion extending between thefirst side portion and the second side portion. This one-piece plasticshell includes at least one layer of a reaction-injection-moldedmaterial.

One advantage of the invention is that a RIM cart is provided that has asimple construction with substantially few components for minimizingmanufacturing cycle time, as well as costs associated therewith.

Another advantage of the invention is that a RIM cart is provided thathas a substantially efficient construction for maintaining items withina predetermined temperature range.

Yet another advantage of the present invention is that a RIM cart isprovided that has a substantially light-weight construction forincreasing the available payload capacity of an aircraft.

Still another advantage of the present invention is that an automatedmethod for manufacturing a galley cart is provided that utilizescomputer-controlled mechanisms for improving manufacturing precision andconsistently producing a uniform product quality.

The features, functions, and advantages can be achieved independentlyand in various embodiments of the present invention or may be combinedin yet other embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this invention, reference shouldnow be made to the embodiments illustrated in greater detail in theaccompanying drawings and described below by way of examples of theinvention:

FIG. 1 is an exploded view of a RIM cart for an aircraft, according toone advantageous embodiment of the claimed invention;

FIG. 2 is a partially cutaway cross-sectional view of the RIM cart shownin FIG. 1, as taken along line 2-2;

FIG. 3 is a perspective view of a castor coupled to a bottom side of theRIM cart shown in FIG. 1;

FIG. 4 is a perspective view of the RIM cart shown in FIG. 1,illustrating a decorative panel being attached to the galley cart;

FIG. 5 is a cross-sectional view of the RIM cart shown in FIG. 4, astaken along line 5-5;

FIG. 6 is a perspective view of a system for manufacturing the RIM cartshown in FIG. 1;

FIG. 7 is a cross-sectional view of the system shown in FIG. 4,illustrating a second mold being clamped to a first mold for forming aone-piece plastic shell therebetween; and

FIG. 8 is a logic flow diagram of a method for manufacturing the RIMcart shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

In the following figures the same reference numerals are utilized fordesignating the same or similar components in the various views.Moreover, the illustrated embodiments described herein employ featureswhere the context permits, e.g. when a specific result or advantage ofthe claimed invention is desired. Specifically, the embodimentsdescribed herein implement a reaction-injection-molded galley carthaving a base layer and a foam layer with reinforcement fibers embeddedtherein. However, it is contemplated that the galley cart can includemore or less layers and also lack the reinforcement fibers as desired.In this respect, it will be appreciated that various embodiments arecontemplated having different combinations of the described features,having features other than those described herein, or lacking one ormore of those features. For these reasons, it is understood that theinvention can be carried out in various suitable modes.

Referring to FIG. 1, there is shown an exploded view of areaction-injection-molded galley cart 10 (“RIM cart”) for an aircraft,according to one advantageous embodiment of the claimed invention. TheRIM cart 10 generally includes three primary components, namely aone-piece plastic shell 12, a pair of panels 14, 16 coupled to opposingsides 18, 20 of the shell 12, and a tray member 22 coupled to a top sideportion 24 of the shell 12. However, it is contemplated that the RIMcart 10 can instead include more or less than three primary componentsas desired. For instance, the one-piece plastic shell 12 can instead bemanufactured as a sub-assembly of two or more separate sub-components.Also, the tray member 22 can instead be an integral part of the shell 12thereby decreasing the number of primary components to two. It will alsobe appreciated that the RIM cart 10 can include other suitable primarystructures as desired.

In this embodiment, the one-piece plastic shell 12 has a cylindricalconstruction with a generally rectangular cross-section. However, it isunderstood that the one-piece plastic shell 12 can have a variety ofother suitable constructions as desired. Specifically, in thisembodiment, the one-piece plastic shell 12 includes a first side portion28, a second side portion 30 that is spaced apart from the first sideportion 28, a top side portion 24 extending between the first sideportion 28 and the second side portion 30, and a bottom side portion 32extending between the first side portion and the second side portion 30.

Moreover, as best shown in FIG. 2, the one-piece plastic shell 12 iscomprised of a base layer 34 and a foam layer 36 coupled to the baselayer 34. However, it is contemplated that more or less than the baselayer 34 and the foam layer 36 can be utilized as desired.

The base layer 34 defines an interior of the RIM cart 10 and iscomprised of a material that is generally impermeable to fluids. In thisregard, the base layer 34 can be easily cleaned when food or beveragesare spilled inside the RIM cart 10. In addition, the base layer 34 canalso prevent beverages from leaking through the shell 12. Furthermore,this impermeable base layer 34 can prevent air from passing between theinterior 38 of the RIM cart 10 and the exterior 40. This feature isbeneficial for improving the thermal insulation properties of the shell12. In this embodiment, the base layer 34 is comprised of high-densitypolyurethane. However, the base layer 34 can instead be comprised ofvarious other suitable materials as desired. For example, it iscontemplated that an outer layer of aluminum sheating or skin can becoupled to the foam layer 36.

Also in this embodiment, the foam layer 36 is areaction-injection-molded material (“RIM material”) that is coupled tothe base layer 34. This foam layer 36 is substantially lightweight andhas a substantially low coefficient of thermal conduction. In this way,the foam layer 36 provides a substantial heat transfer barrier formaintaining the interior 38 of the RIM cart 10 within a predeterminedtemperature range.

In addition, the foam layer 36 has a series of reinforcement members 42embedded therein for strengthening the foam layer 36. Thesereinforcement members 42 are chopped carbon fibers. However, it iscontemplated that the reinforcement members 42 can instead becontinuously woven carbon fibers, chopped glass fibers, continuouslywoven glass fibers, various other suitable reinforcement structures andmaterials, or any suitable combination thereof.

The first side portion 28 and the second side portion 30 have a seriesof grooves 44 formed therein for receiving and supporting one or morefood trays 46 within the interior 38 of the RIM cart 10.

Referring back to FIG. 1, the panels 14, 16 preferably are doors havingtwo or more conventional hinge elements 48 and are coupled to theopposing ends 18, 20 of the shell 12. Each panel 14, 16 also has a doorfastener 54 for selectively attaching to the one-piece plastic shell 12and securing the door in the closed position. In this embodiment, thedoor fastener 54 is a conventional cam-latch device. However, it will beappreciated that various other suitable fasteners can be utilized asdesired and also that only one of the panels 14, 16 can be a doorinstead of both.

Referring now to FIG. 3, the RIM cart 10 further includes four castors58 coupled to the bottom side portion 32 of the one-piece plastic shell12. However, it is understood that more or less than four castors 58 canbe utilized as desired. Each castor 58 includes a sleeve portion 60 thatis insert-molded, embedded within, or otherwise coupled to the bottomside portion 32 of the one-piece plastic shell 12. Each sleeve portion60 is utilized for receiving a rod member 62 with a wheel 64 mountedthereon. In this way, the rod member 62 and the wheel 64 can swivelwithin the sleeve portion 60 for allowing the RIM cart 10 to be rolledin various directions. Moreover, each sleeve portion 60 has an annulargroove 66 formed therein for receiving an annular flange 68 extendingfrom the rod member 62. In this respect, the rod member 62 is rotatablycoupled to the sleeve portion 60.

Referring now to FIGS. 4 and 5, the first side portion 28 furtherincludes a pair of detent flanges 70 extending therefrom for mounting adecorative panel 71 to the one-piece plastic shell 12. However, it isunderstood that various other suitable fasteners can be utilized insteadof the detent flanges 70. Also, it will be appreciated that thedecorative panel 71 or other suitable structure can be mounted otherportions of the RIM cart 10 as desired.

The pair of detent flanges 70 block upward and downward movement of thedecorative panel 71. Additionally, as best shown in FIG. 4, the flanges70 receive the decorative panel 71 in a direction along the length ofthe RIM cart 10. The decorative panel 71 is further secured to the firstside portion 28 via four fasteners, e.g. threaded screws. However, it isunderstood that various other suitable fasteners can be utilized asdesired. It

Referring now to FIG. 6, there is shown a perspective view of a system72 for manufacturing the RIM cart 10 shown in FIG. 1. This system 72includes a first mold 74 and a base-resin applicator 76 for applying thebase layer to the first mold 74. The system 72 further includes afoam-resin applicator 78 for applying one or more layers of RIM materialto the base layer 34 on the first mold 74 so as to form the one-pieceplastic shell 12. One skilled in the art will understand that having thebase-resin applicator 76 and a separate foam-resin applicator 78 canprevent mixture of the base resin and the RIM material as desired.However, it is understood that the system 72 can omit the base-resinapplicator 76 as desired and utilize only one application device toapply the two resins.

In this embodiment, the first mold 74 is rotatable about an axis 80.Also, the base-resin applicator 76 and the foam-resin applicator 78 aremovable along one or more axes 82, 84, 86. The first mold 74 and theapplicators 76, 78 are coupled to motors 88, 90 which are coupled to andcontrolled by a controller 92. In this way, the controller 92 can movethe first mold 74, the base-resin applicator 76, and the foam-resinapplicator 78 and also actuate the applicators 76, 78 to apply the RIMmaterial onto the first mold 74. As a result, this feature allows theRIM material to be applied to the first mold 74 within a substantiallyshort period of time so as to increase the production rates of shells 22and decrease manufacturing costs associated therewith. This feature isalso beneficial for maintaining the consistency in the structures of themanufactured shells 22. Further, the controller 92 can actuate theapplicators 76,78 for applying additional resin to predeterminedportions of the shell 12 for increasing the thickness and the strengthof the shell 12 in those regions of the shell 12.

It will be appreciated that the first mold 74 can remain fixed inposition while the applicators 76, 78 are moved around the first mold74. Likewise, it is contemplated that the applicators 76, 78 can remainfixed in position while the first mold 74 rotates about its axis 80 andreciprocates along that axis 80. In this way, it is understood that lessmotors can be included as desired.

The system 72 further includes a RIM sub-system 73 for supplying the RIMmaterial to the foam-resin applicator 78. In this embodiment, the RIMsub-system 73 generally includes two liquid supply lines, namely anisocyanate supply line 94 and a polyol supply line 96. Isocyanate andpolyol are stored within their respective temperature-controlled feedtanks 98, 100. The isocyanate supply line 94 has a heat exchanger 102integrated within. Also, the polyol supply line 96 has a water inlet104, a water outlet 106, and a nucleator 108 integrated therein. It isunderstood that each supply line 94, 96 can contain various otherconventional components as desired.

Each feed tank 98, 100 is coupled to its respective metering valve 110,112 via the supply line 94, 96. The metering valve 110, 112 are coupledto the controller 92 and are operated by the controller 92 forregulating the pressure and the amount of isocyanate and polyoldelivered to a mixing chamber within the foam-resin applicator 78.Thereafter, the RIM material is discharged from the foam-resinapplicator 78 and applied to the first mold 74.

In this embodiment, the system 72 further includes a fiber supply tank116 coupled to a regulator valve 118 for supplying chopped fibers 42 tothe RIM material in the mixing chamber and producing structuralreaction-injection-molded material (“SRIM material”). In this way, thefoam-resin applicator 78 can apply resin with fiber reinforcementsembedded therein. This feature is beneficial for providing substantialstrength to the construction of the shell 12. However, it will beappreciated that the fiber supply tank 116 and the regulator valve 118can be omitted from the system as desired.

As best shown in FIG. 7, the system 72 also includes a second mold 120for clamping to the first mold 74. In this way, pressure and heat can beapplied to the base layer 34 and the foam layer 36 for producing theone-piece plastic shell 12.

Referring now to FIG. 8, there is shown a logic flow diagram of a methodfor manufacturing the RIM cart shown in FIG. 1. This method commences instep 200 and them immediately commences to step 202.

In step 202, a series of fasteners are attached to the first mold 74.These fasteners can include the sleeve portions 60 of the castors 58,the hinge elements 48 for attaching the door panels 14, 16 to the shell12, the detent flanges 70 for mounting the decorative panels 14, 16 tothe side portions 28, 30, various other suitable fasteners embeddedwithin the shell 12, or any combination thereof as desired. One skilledin the art will appreciate that these fasteners are only attached to thefirst mold 74 for the duration of the molding process. Then, the methodproceeds to step 204.

In step 204, the controller 92 actuates the motor 88 and rotates thefirst mold 74 about its axis 80. However, as described hereinabove, itis contemplated that the controller 92 can instead actuate motors 90 formoving the applicators 76, 78 around a stationary first mold 74. It willbe appreciated that the first mold 74, the base-resin applicator 76, thefoam-resin applicator 78, or any combination thereof may be moved via apredetermined program or secured in a fixed position as desired. Thesequence then proceeds to step 206.

In step 206, the controller 92 actuates the base-resin applicator 76 forapplying the base layer 34 to the external surfaces of the first mold74. As detailed hereinabove, this base layer 34 is utilized for definingthe interior of the RIM cart 10 and is generally impermeable to fluids.However, it will be appreciated that step 206 can be omitted as desired.The sequence then proceeds to step 208.

In step 208, the controller 92 actuates the foam-resin applicator 78 andcauses the foam-resin applicator 78 to apply a SRIM layer onto the baselayer 34. Specifically, the controller 92 actuates the metering valve110, 112 within the RIM sub-system 73 for delivering predeterminedamounts of isocyanate and polyol to the mixing head of the base-resinapplicator 76 at a predetermined pressure. In addition, the controller92 actuates the regulator valve 118 for supplying a predetermined amountof reinforcement fibers 42 to the isocyanate and polyol within themixing head. Thereafter, the mixture of the isocyanate, polyol, andfibers or SRIM material is applied to the first mold 74.

Also in this step, the controller 92 regulates the motors 88, 90respectively coupled to the foam-resin applicator 78 and the first mold74. In this way, the controller 92 can move the first mold 74 and thefoam-resin applicator 78 for applying a predetermined amount of the RIMmaterial to predetermined portions of the first mold 74. For thatreason, it will be appreciated that the system 72 can also includeposition sensors (not shown). This feature is advantageous because thesystem 72 can produce a substantial number of carts consistently withinsubstantially small tolerances. Additionally, the system 22 can providelarger wall thicknesses to predetermined portions of the shell 12 andincrease the strength of those portions of the shell 12. Then, thesequence proceeds to step 210.

In step 210, the controller 92 actuates the foam-resin applicator 78 forapplying RIM material to the onto the SRIM layer. Specifically, thecontroller 92 closes the regulator valve 118 and discontinues the supplyof reinforcement fibers 42 to the mixing head. The controller 92continues to actuate the RIM sub-system 73 for supplying isocyanate andpolyol to the mixing head. Then, the mixture of isocyanate and polyol orthe RIM material is applied onto the SRIM layer. In this regard, thereinforcement fibers 42 are substantially embedded within the foam layer36 of RIM material. The controller 92 then actuates the foam-resinapplicator 78 to stop applying the RIM material to the first mold 74. Inthis embodiment, the controller 92 closes the metering valve 110, 112and actuates the motors 88, 90 to halt the rotation of the first mold 74and the movement of the foam-resin applicator 78. Then, the sequenceproceeds to step 212. Thereafter, the sequence proceeds to step 212.

In step 212, the second mold 120 is clamped to the first mold 74 forapplying a predetermined amount of pressure and heat to the base layer34 and the foam layer 36. This RIM process requires substantially lowpressure and substantially low heat. These features are advantageous forincreasing tool life, minimizing tool maintenance, and decreasing costsassociated therewith. The sequence then proceeds to step 214.

In step 214, the one-piece plastic shell 12 is removed from the firstmold 74 and the second mold 120 for trim and finish treatment. Forexample, in this step, any flashing, which resulted from a gap betweenthe interface of the first mold 74 and the second mold 120, is removed.Then, the sequence proceeds to step 216.

In step 216, the tray member 22, the wheels 128, and the pair of panels14, 16 are coupled to the one-piece plastic shell 12. Specifically, thepair of panels 14, 16 is coupled to their respective hinge elements 48,which are extending from the opposing ends 18, 20 of the shell 12.Additionally, the rod members 62 of the castors 58 are inserted into thesleeve portions 60 that are embedded within the bottom side portion 32of the shell 12. Moreover, the decorative panels 14, 16 are attached tothe first side portion 28 or the second side portion 30 of the shell 12via the detent flanges 70.

While particular embodiments of the invention have been shown anddescribed, numerous variations and alternate embodiments will occur tothose skilled in the art. Accordingly, it is intended that the inventionbe limited only in terms of the appended claims.

1. A reaction-injection-molded galley cart for an aircraft, comprising:a body configured to move along a passenger aisle of the aircraft, saidbody having a one-piece plastic shell that forms a first side portion, asecond side portion, a top side portion, and a bottom side portion ofsaid body; wherein said first side portion is spaced apart from saidsecond side portion; wherein said top side portion extends between saidfirst side portion and said second side portion; wherein said bottomside portion extends between said first side portion and said secondside portion; wherein said one-piece plastic shell includes at least onelayer of a reaction-injection-molded material.
 2. Thereaction-injection-molded galley cart recited in claim 1 wherein said atleast one layer of reaction-injection-molded material has a plurality offasteners embedded therein.
 3. The reaction-injection-molded galley cartrecited in claim 1 wherein said plurality of fasteners is selected fromthe group consisting of a plurality of castors, a plurality of hinges,and a plurality of detent flanges.
 4. The reaction-injection-moldedgalley cart recited in claim 1 wherein said plurality of fastenersmounts at least one decorative panel to said body.
 5. Thereaction-injection-molded galley cart recited in claim 1 wherein said atleast one layer of reaction-injection-molded material includes a baselayer and a foam layer coupled to said base layer.
 6. Thereaction-injection-molded galley cart recited in claim 1 wherein saidtop side portion of said one-piece plastic shell has a tray membercoupled thereto.
 7. The reaction-injection-molded galley cart recited inclaim 1 wherein said one-piece plastic shell defines an interior cavityand a pair of opposing open ends in communication with said interiorcavity, said pair of opposing open ends having a pair of panels coupledthereto.
 8. The reaction-injection-molded galley cart recited in claim 7wherein at least one said pair of panels is a door for selectivelyproviding access to said interior cavity.
 9. Thereaction-injection-molded galley cart recited in claim 1 wherein saidone-piece shell construction has a plurality of grooves formed thereinfor receiving and supporting at least one tray within said interiorcavity.
 10. The reaction-injection-molded galley cart recited in claim 9wherein said plurality of grooves are formed in said first side portionand said second side portion.
 11. A reaction-injection-molded galleycart for an aircraft, comprising: a body configured to move along apassenger aisle of the aircraft, said body having a one-piece plasticshell that forms a first side portion, a second side portion, a top sideportion, and a bottom side portion of said body; wherein said first sideportion is spaced apart from said second side portion; wherein said topside portion extends between said first side portion and said secondside portion; wherein said bottom side portion extends between saidfirst side portion and said second side portion; wherein said one-pieceplastic shell includes at least one layer of a reaction-injection-moldedmaterial with a plurality of reinforcement members embedded therein. 12.The reaction-injection-molded galley cart recited in claim 11 whereinsaid plurality of reinforcement members includes at least one of aplurality of carbon fibers and a plurality of glass fibers.
 13. Thereaction-injection-molded galley cart recited in claim 11 wherein saidat least one layer of reaction-injection-molded material has a pluralityof fasteners embedded therein.
 14. The reaction-injection-molded galleycart recited in claim 11 wherein said plurality of fasteners is selectedfrom the group consisting of a plurality of castors, a plurality ofhinges, and a plurality of detent flanges.
 15. Thereaction-injection-molded galley cart recited in claim 11 wherein saidplurality of fasteners mounts at least one decorative panel to saidbody.
 16. The reaction-injection-molded galley cart recited in claim 11wherein said at least one layer of reaction-injection-molded materialincludes a base layer and a foam layer coupled to said base layer. 17.The reaction-injection-molded galley cart recited in claim 11 whereinsaid top side portion of said one-piece plastic shell has a tray membercoupled thereto.
 18. The reaction-injection-molded galley cart recitedin claim 11 wherein said one-piece plastic shell defines an interiorcavity and a pair of opposing open ends in communication with saidinterior cavity, said pair of opposing open ends having a pair of panelscoupled thereto.
 19. The reaction-injection-molded galley cart recitedin claim 18 wherein at least one said pair of panels is a door forselectively providing access to said interior cavity.
 20. Thereaction-injection-molded galley cart recited in claim 11 wherein saidone-piece shell construction has a plurality of grooves formed thereinfor receiving and supporting a tray within said interior cavity.
 21. Thereaction-injection-molded galley cart recited in claim 20 wherein saidplurality of grooves are formed in said first side portion and saidsecond side portion.
 22. The reaction-injection-molded galley cartrecited in claim 11 wherein said base layer is generally impermeable tofluids.
 23. A system for manufacturing a reaction-injection-moldedgalley cart for an aircraft, comprising: a first mold; a resinapplicator device for applying at least one layer ofreaction-injection-molded material to said first mold; a second mold forclamping to said first mold and forming a one-piece plastic shell; atleast one motor coupled to at least one of said first mold, said resinapplicator device, and said second mold; a controller coupled to said atleast one motor for controlling movement of at least one of said firstmold, said resin applicator device, and said second mold; wherein saidone-piece plastic shell has a first side portion, a second side portionspaced apart from said first side portion, a top side portion extendingbetween said first side portion and said second side portion, and abottom side portion extending between said first side portion and saidsecond side portion.
 24. A reaction-injection-molded galley cart for anaircraft manufactured by the process comprising: rotating a first mold;applying a base layer to said first mold; applying a foam layer to saidbase layer; embedding at least one reinforcement member in at least oneof said base layer and said foam layer; halting a spin of said firstmold; clamping a second mold to said first mold; applying pressure tosaid base layer and said foam layer; and heating said base layer andsaid foam layer; and wherein said base layer and said foam layer form aone-piece plastic shell with a first side portion, a second side portionspaced apart from said first side portion, a top side portion extendingbetween said first side portion and said second side portion, and abottom side portion extending between said first side portion and saidsecond side portion; wherein at least said foam layer comprisesreaction-injection-molded material.
 25. A method for manufacturing areaction-injection-molded galley cart for an aircraft, comprising:rotating a first mold; applying a base layer to said first mold;applying a foam layer to said base layer; halting a spin of said firstmold; clamping a second mold to said first mold; applying pressure tosaid base layer and said foam layer; and heating said base layer andsaid foam layer; wherein said base layer and said foam layer form aone-piece plastic shell with a first side portion, a second side portionspaced apart from said first side portion, a top side portion extendingbetween said first side portion and said second side portion, and abottom side portion extending between said first side portion and saidsecond side portion; wherein said foam layer comprisesreaction-injection-molded material.
 26. The method recited in claim 25further comprising: applying an outer layer to said foam layer.
 27. Themethod recited in claim 25 further comprising: securing at least onefastener to at least on of said first mold and said second mold; andembedding said at least one fastener in at least one of said base layerand said foam layer.
 28. The method recited in claim 25 furthercomprising: coupling a tray member to said top side portion of saidone-piece plastic shell.
 29. The method recited in claim 25 furthercomprising: coupling a pair of panels to a pair of opposing ends of saidone-piece plastic shell.
 30. The method recited in claim 29 wherein atleast one of said pair of panels is a door for selectively providingaccess to an interior cavity that is defined by said one-piece plasticshell.
 31. The method recited in claim 25 further comprising: coupling aplurality of wheels to said bottom side portion of said one-pieceplastic shell.
 32. A method for manufacturing areaction-injection-molded galley cart for an aircraft, comprising:rotating a first mold; applying a base layer to said first mold;applying a foam layer to said base layer; embedding a plurality ofreinforcement members within at least one of said base layer and saidfoam layer; halting a spin of said first mold; clamping a second mold tosaid first mold; applying pressure to said base layer and said foamlayer; and heating said base layer and said foam layer; and actuating acomputer-controlled mechanism for moving at least one of said firstmold, said second mold, and a resin applicator device; wherein said baselayer and said foam layer form a one-piece plastic shell with a firstside portion, a second side portion spaced apart from said first sideportion, a top side portion extending between said first side portionand said second side portion, and a bottom side portion extendingbetween said first side portion and said second side portion; whereinsaid foam layer comprises reaction-injection-molded material.
 33. Themethod recited in claim 32 further comprising: applying an outer layerto said foam layer.
 34. The method recited in claim 32 furthercomprising: securing at least one fastener to said first mold; andembedding said at least one fastener in at least one of said base layerand said foam layer.
 35. The method recited in claim 32 furthercomprising: coupling a tray member to said top side portion of saidone-piece plastic shell.
 36. The method recited in claim 32 furthercomprising: coupling a pair of panels to a pair of opposing ends of saidone-piece plastic shell.
 37. The method recited in claim 36 wherein atleast one of said pair of panels is a door for selectively providingaccess to an interior cavity that is defined by said one-piece plasticshell.
 38. The method recited in claim 32 further comprising: coupling aplurality of wheels to said bottom side portion of said one-pieceplastic shell.